Method and system for providing articles with rigid foamed cementitious cores

Abstract

One aspect of the present invention pertains to an apparatus for forming a rigid foamed cementitious core within a plurality of article shells. In general, the apparatus can be comprised of a shell bank for retaining a plurality of article shells and comprising a sled and a plurality of reinforcement shells, a filing station for delivering a gas-entrained cementitious material, and a pump. The gas-entrained cementitious material cures to form a rigid foamed cementitious core within each article shell in the plurality of article shells.

Description

CROSS-REFERENCE TO A RELATED APPLICATION[0001]This application is a continuation-in-part of U.S. patent application Ser. No. 10 / 131,056, filed Apr. 24, 2002, entitled “High Performance Door”, which is hereby incorporated by reference.BACKGROUND OF THE INVENTION[0002]1. Field of the Invention[0003]One aspect of the present invention is generally directed to at least one method and system for providing articles with rigid foamed cementitious cores.[0004]2. Background Art[0005]Door systems have been designed to pass security tests, such as British standard PAS 23 (PAS 23), British standard PAS 24 (PAS 24), and Florida Building Code Test TAS / PA 201 (TAS / PA 201). These door systems are customarily designed to prevent forcible entry by tools as defined by PAS 23 and PAS 24 and to pass an impact test simulating large missile debris impact during high velocity wind storms, such as hurricanes or typhoons, as defined by TAS / PA 201.[0006]Many steel doors pass some security tests. However, thes...

AI Technical Summary

Benefits of technology

[0011]An aspect of the present invention provides doors that resist denting and are reasonably priced.

[0019]The sled can be comprised of a first and second sled panel. A plurality of casters can be attached to at least one edge of the sled for facilitating movement of the sled around the assembly floor.

[0020]In another embodiment, the filling station can further include a platform for aiding in the delivery of the gas-entrained cementitious material into the interior of each door shell.

Problems solved by technology

However, these doors are less desirable as entry way doors since they lack aesthetic detail, rust and dent readily.

For example, entry way doors to common areas in apartment complexes and hotels experience significant use and receive substantial physical abuse, lending to significant rusting and denting.

By way of another example, entry way doors along salt water coasts receive substantial physical abuse and are susceptible to corrosive chemical attack.

However, these doors have had difficulty meeting the requirements of PAS 23 and PAS 24.

These results are unacceptable to certain customers, particularly public housing officials who control specifications for apartments in the United Kingdom and to building code officials in high velocity wind zone areas, such as Florida in the United States.

Images